Thermoformed protective face shield

ABSTRACT

A unitary thermoformed protective face shield includes a curved top member adapted to conform to a user&#39;s forehead. The curved top member includes a plurality of exhaust channels formed therein for allowing ventilation. The face shield further includes a visor portion extending outward from a lower end of the curved top member, thereby creating a space between the user&#39;s face and a face cover portion. The face cover portion extends downward from the visor portion and covers and provides protection for the face of a user. A side shield portion extends inwardly from the face cover portion for shielding the sides of a user&#39;s face. Further, a perimeter flange may extend perpendicular to the perimeter of the face shield for providing structural support to the face shield.

FIELD OF THE INVENTION

The embodiments of the invention are generally related to face masks or shields for protecting health care or other personnel.

SUMMARY OF THE INVENTION

A thermoformed protective face shield includes a curved top member adapted to conform to a user's forehead. The curved top member includes a plurality of exhaust channels formed therein for allowing ventilation. The face shield further includes a visor portion extending outward from a lower end of the curved top member, thereby creating a space between the user's face and a face cover portion. The face cover portion extends downward from the visor portion and covers and provides protection for the face of a user. A side shield portion may extend substantially perpendicularly from the face cover portion for shielding the sides of a user's face. Further, a perimeter flange may extend perpendicular to the perimeter of the face shield for providing structural support to the face shield and additional protection to the user.

The above discussed and other features and advantages of the present invention will be appreciated and understood by those of ordinary skill in the art from the following detailed description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Referring now to the drawings, wherein like elements are numbered alike in the several Figures:

FIG. 1 illustrates a perspective view of a face shield of according to an embodiment of the present invention;

FIG. 2 is front view of the face shield illustrated in FIG. 1;

FIG. 3 is a side view of the face shield illustrated in FIG. 1;

FIG. 4 is a top view of the face shield illustrated in FIG. 1;

FIG. 5 is perspective e of the face shield in use.

DESCRIPTION OF THE EMBODIMENTS

The face shield of the disclosed embodiments is illustrated in FIGS. 1-5. Face shield 10 generally includes a curved top portion 15, a visor portion 50, a face cover portion 60, a side shield portion 70 and a perimeter flange 80. The face shield may include a foam pad 30 for increasing the comfort of the user and a strap 90 for securing the face shield to a user.

The curved top portion 15 is shaped to substantially conform to a user's forehead and includes an upper end and a lower end. A plurality of exhaust channels, one of which is indicated at 20, is formed in curved top portion 15. Each exhaust channel 20 includes a top end 24 and a bottom end 22 providing a port for allowing heat and/or moisture to escape from the behind the face cover portion out past the user's forehead. This helps to prevent face shield 10 from fogging and increases user comfort by curtailing heat and/or moisture buildup inside face shield 10.

Curved top portion 15 also includes an outwardly extending step 40, including ledge 35, that provides a space at the bottom end of curved top portion 15, between the user's forehead and the curved top portion 15, for positioning foam pad 30. Foam pad 30 may be formed from any suitable pad material including a closed cell adhesive backed foam or similar material. The materials used for, and dimensions of, foam pad 30 may be selected based upon factors such as the specific size and shape of face shield 10 and/or outwardly extending step 40, the material from which outwardly extending step 40 is made, the weight of face shield 10, the intended use of face shield 10, and the specific user. By way of non-limiting example, foam pad 30 may be about 0.25 inches thick by about 1.0 inches high and about 9.0 inches in length. However, foam having up to a thickness of about 0.750″ may be used, depending on the durometer of the foam. In some embodiments, face shield 10 may be used without foam pad 30. The purpose of foam pad 30 is to add comfort, improve stability during movement, and to act as a sweat band for the user.

In addition, curved top portion 15 includes a positioning wedge 25 extending outwardly from a center portion thereof. Positioning wedge 25 is provided to retain strap 90 in place along the lower end of the curved top portion 15. As shown in FIG. 5, strap 90 is located under positioning wedge 25 adjacent to outwardly extending step 40. Strap 90 may be of any material and construction that enables it to be placed around and removed from a user's head and that, when placed around a user's head, resists unintentional movement or displacement of face shield 10. For example, strap 90 may be formed at least in part of an elastic material that can be stretched to facilitate placing face shield 10 on, and removing face shield 10 from, a user's head and that, when face shield 10 is on a user's head, helps secure it in place through tension provided by the elastic. Alternatively, strap 90 may be a non-elastic material, such as nylon, polyester, leather, cotton, or other, provided with a releasable closure that allows strap 90 to be placed on a user's head, tightened as desired for use of face shield 10, and loosened for removal from a user's head. Examples of releasable closures include hook-and-loop and buckles. In one embodiment, strap 90 may be a 0.5 inch wide and 30 inch long hook & loop strap.

Face shield 10 also includes a visor portion 50 extending outwardly or substantially perpendicularly, in a forward direction, away from the user, from the lower end of curved top portion 15. Visor portion 50 provides a space between a user's face and face cover portion 60, as shown in FIG. 5. Face cover portion 60 extends downward from visor portion 50 over a user's eyes, nose, and mouth. At least face cover portion 60, visor portion 50, and side shield portion 70 are formed from an optically clear material, thereby allowing a user to clearly see through face shield 10 at all angles. As previously discussed, heat and moisture can build up in the space between a user's face and face cover portion 60 causing fogging of face cover portion 60. Plurality of channels 20 provide an exhaust mechanism for such heat and moisture to escape. In particular, heat and moisture that could potentially build up behind face cover portion 60 enters the bottom ends 22 of the channels 15 and escapes out the upper ends 24 of the channels 15. Thus, the buildup of heat and moisture, and any resulting fogging, is reduced or prevented.

Side shield portion 70 is made up of a plurality of side segments extending rearwardly from face cover portion 60. In the embodiment shown in FIG. 2, side shield portion 70 is made up of seven side segments. The side segments are relatively planar segments that come together at angles to provide a shield that surrounds the sides and bottom of a user's face. As shown for example in FIG. 5, intermediate side segments 75 may also be included between the side segments and the face cover portion 60 to provide a more conformed and thorough fit.

Face shield 10 may include a perimeter flange 80 extending approximately perpendicularly from the perimeter of the face shield 10. As shown in FIG. 1, perimeter flange 80 extends from the curved top portion 15 and side shield portion 70 such that the perimeter flange 80 is present around the perimeter of face shield 10. Perimeter flange 80 provides structural support and integrity to face shield 10 regardless of the starting thickness of the material used to mold face shield 10. Slots 85 are formed in perimeter flange 80 for positioning strap 90.

Face shield 10 may be formed as a one-piece unit from a transparent, optical grade, thermoplastic material. The process for forming face shield 10 includes heating a plastic sheet before bringing it over a mold cavity and utilizing vacuum to form the sheet to the mold cavity. After removing the formed part from the mold cavity, the perimeter of the formed part is trimmed from a web of the sheet using a die, and slots 85 for the strap are cut. In addition, face shield 10 may be customized to fit a particular user by trimming, as with scissors. Alternatively, one or more portions of face shield 10 may be formed as separate pieces and then joined by any suitable means, including ultrasonic welding or gluing.

Any suitable thickness of material may be used to mold face shield 10. In one embodiment, the material may be from about 0.025 inches thick to about 0.156 inches thick. Typically, a medical grade Polyethylene terephthalate glycol (PETG) is used. However, other suitable materials include polyvinyl chloride (PVC), Polycarbonate, or Polyethylene terephthalate (RPET). The material is light weight to provide a lightweight comfortable face shield that may be comfortably worn for prolonged periods of time.

While some exemplary embodiments have been shown and described, various modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the present invention has been described by way of illustrations and not limitation. 

1. A thermoformed protective face shield comprising: a curved top member having a bottom end and a top end and being longitudinally curved to conform to a user's forehead, said curved top member including a plurality, of exhaust channels, each one of said plurality of exhaust channels having a first end positioned adjacent to the bottom end of the curved top member and a second end positioned adjacent to the top end of the curved top member for allowing moisture and/or heat to escape; a visor portion extending outwardly from a lower end of the curved top member; a face cover portion extending downward from the visor portion for shielding the face of a user; a side shield portion extending inwardly from the face cover portion for shielding the sides of a user's face; and a perimeter flange extending perpendicular to the perimeter of the face shield for providing structural support to the face shield.
 2. The thermoformed protective face shield of claim 1, further comprising a positioning wedge extending outwardly from a center portion of said curved top member.
 3. The thermoformed protective face shield of claim 1, wherein said curved top member comprises an outwardly extending step configured to provide a space between a user's forehead and said curved top member.
 4. The thermoformed protective face shield of claim 3, further comprising a foam pad positioned in said outwardly extending step.
 5. The thermoformed protective face shield of claim 4, wherein said foam pad has a thickness of 0.25 inches to 0.75 inches.
 6. The thermoformed protective face shield of claim 5, wherein said foam pad has a length of about 9.0 inches.
 7. The thermoformed protective face shield of claim 4, wherein said foam pad is comprised of a closed cell adhesive backed foam.
 8. The thermoformed protective face shield of claim 1, further comprising a strap for securing said thermoformed protective face shield to a user.
 9. The thermoformed protective face shield of claim 8, wherein said curved top member comprises: a) a positioning wedge extending outwardly from a center portion of said curved top member, and b) an outwardly extending step configured to provide a space between a user's forehead and said curved top member, further wherein said strap is located under said positioning wedge and adjacent to said outwardly extending step.
 10. The thermoformed protective face shield of claim 8, wherein said perimeter flange comprises slots for positioning said strap.
 11. The thermoformed protective face shield of claim 8, wherein said strap is formed of an elastic material.
 12. The thermoformed protective face shield of claim 8, wherein said strap is formed of a non-elastic material, said strap further comprising a releasable closure that can be tightened and loosened.
 13. The thermoformed protective face shield of claim 12, wherein said strap is a hook-and-loop strap.
 14. The thermoformed protective face shield of claim 1, wherein said side shield portion comprises a plurality of side segments extending rearwardly from said face cover portion.
 15. The thermoformed protective face shield of claim 14, wherein said side segments are planar and come together at an angle to provide a shield that is adapted to surround the sides and bottom of a user's face.
 16. The thermoformed protective face shield of claim 14, further comprising intermediate side segments positioned between said side shield portion and said face cover portion.
 17. The thermoformed protective face shield of claim 1, wherein said perimeter flange is present around the entire perimeter of said thermoformed protective face shield.
 18. The thermoformed protective face shield of claim 1, wherein at least said visor portion, said face cover portion, and said side shield portion are formed from an optically clear material.
 19. The thermoformed protective face shield of claim 1, formed as a one-piece unit from an optically clear thermoplastic material.
 20. The thermoformed protective face shield of claim 19, wherein said optically clear thermoplastic material is polyethylene terephthalate glycol, polyvinyl chloride, polycarbonate, or polyethylene terephthalate.
 21. The thermoformed protective face shield of claim 20 wherein said optically clear thermoplastic material has a thickness of from about 0.025 inches to about 0.156 inches. 